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I'm planning on using a banjo bolt oil return fitting. I know this is controversial, but please put that aside for a moment, and consider my question:

The shortest and cleanest path to the oil pan for my return line seems to be between the header and the cross member. It's a tight fit, and I'm worried that the header will melt the rubber return hose.

I'm thinking maybe the header's heat shield will be enough to make this okay, but I don't have a good feel for exactly how hot the outside of the heat shield gets in relation to how much the rubber can withstand (it's a Goodyear ACALA hose, if there are any engineers out there with datasheets for that sort of thing).

Will this be okay? If not, the hose will have to take a much less direct path.

I really dislike my steel braided return line and would much rather go with something else. I also run right next to the exhaust manifold as I'm sure most people do. What kind of line are you going with that's not steel braided and where can I get about 2 feet?

Ryan - I'll see if I can get a better shot of it for you when I get to work on my car in the air (hopefully tomaro). Thinking back to it, though, I think no matter what if you're going banjo bolt then you're going to have to go by the header there. The one thing that was supposed to be bad about banjo, just FYI, was that supposedly it didn't flow to well since it was below the level of oil in the pan.

I am guessing you are using a Legacy turbo header and up-pipe - I have the braided line with banjo bolt fitting return from iSR on my car with the Legacy downpipe, and the line runs down right beside that up-pipe (there is heat shield on the up-pipe) and it works just fine.

mike well if you want to use rubber hose then just a barbed 1/2" fitting but if you want to get the largest threaded fitting you can get from like Russel I don't remember how the fittign sizes go but ideallly you want the largest ID hose so that the oil free flows w/ gravity.

For a #12 Earls weld fitting, the part number is 967112 or 967110 for a #10. You would also want a 45 degree or straight fitting to bolt onto that which the straight in a #12 is 800112. I bought this one originally, but will replace it with a 45 degree possibly in the near future. For the line, you'll need about 2' of #12 (or #10) which is 400120.

As for connecting the line to the turbo, I don't know what you'll need. Mine is a slip fitting.